SERVICE INFORMATION LETTER

AVOX Systems Inc., 225 Erie Street, Lancaster NY 14086-9502 USA

Tel: 716-683-5100 • Fax: 716-681-1089 • Vendor Code: 53655

US DOT RULE CHANGE REQUIRES REPLACEMENT OF PRESSURE RELIEF DEVICE (ALSO

REFERRED TO AS SAFETY OUTLET) ON CERTAIN P/N 801293 SERIES AND 801365 SERIES
CYLINDER AND REGULATOR ASSEMBLIES (CRA’S) IN ORDER TO SHIP BY AIR AS CARGO OR
COMPANY OWNED MATERIAL (COMAT) WHEN FILLED WITH OXYGEN.

SUMMARY
US DOT has issued a new rule governing the shipment of cylinder and regulator assemblies containing
oxygen by air as cargo or COMAT after October 1, 2008. The new rule requires a pressure relief device
(PRD) with a pressure range from 90 to 100 percent of the cylinder test pressure for cylinder type 3AA. Some
AVOX Systems CRA’s which include DOT Type 3AA steel cylinders were manufactured with a PRD that does
not conform to the new rule.
1. PLANNING INFORMATION
A. Effectivity
(1) Concerned equipment
This Service Information Letter applies to the CRA's listed in Table 1.
Table 1
End Item P/N’s of Affected P/N 801293 Series and 801365 Series CRA’s
801293-00 801365-10
801293-04 801365-11

(2) Aircraft
At the time of this Service Information Letter, 801293 Series CRA's were known to be operating
on Gulfstream and Raytheon aircraft and 801365 Series CRA's were known to be operating on
Cessna aircraft.
(3) On production line
CRA’s manufactured after January 1, 2008 will have a new safety outlet installed in the regulator.
(4) This Service Information Letter also applies to all units held in stores for service on the aircraft
listed in (2).
B. Reason
(1) The new US DOT rule (US 49 CFR 173.302(f)) changes the rating of the PRD on a charged CRA
that has a type 3AA cylinder when offered for transport aboard an aircraft as cargo or COMAT
after the time of the first hydrostatic test and requalification following October 1, 2008.
(2) This new rule does not affect CRA’s installed in aircraft as part of the required equipment for flight
unless the CRA is removed and offered for shipment as cargo or COMAT.

(3) It is recommended that the PRD be changed to comply at the next hydrostatic test, but no later
than the first hydrostatic test after October 1, 2008.

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 C. Description
(1) At the next hydrostatic test, but no later than the first hydrostatic test after October 1, 2008,
replace a non-compliant PRD with a PRD that complies with the new rule. There is one PRD on
a CRA.

(2) Install a label on the cylinder to indicate that the cylinder complies with the new rule.

D. Compliance
This Service Information Letter must be accomplished at the first scheduled hydrostatic test and
requalification after October 1, 2008 to enable the changed CRA to be transported as cargo or
COMAT aboard aircraft.
E. Manpower
(1) One Technician
(2) Estimated time: 30 minutes. (No additional manpower will be required if the unit is being
overhauled).
2. MATERIAL INFORMATION
A. Material – Availability
See Table 2
B. Industry Support Information
Not applicable.
C. Material necessary for Each Unit
Table 2 lists the parts necessary to accomplish this SIL.
(1) Material to be Purchased
One of the safety outlets in Table 2 is required for each CRA to be accomplished. Contact a
location in section 4. APPENDIX of this SIL for prices.
Table 2
Required Materials

Affected New Safety Label P/N Label P/N Avail.

CRA P/N Outlet P/N Qty (min qty=10) Qty (min qty=10) Qty (days)
801293-00 800659-06 1 10014464 1 2824-00 1 90
801293-04 800659-06 1 10014464 1 2824-00 1 90
801365-10 800659-01 1 10014464 1 2824-00 1 90
801365-11 800659-01 1 10014464 1 2824-00 1 90

D. Re-identified Parts
The regulator will be re-identified by stamping the new P/N on the replacement identification label P/N
2824-00 (see Table 3 and Figure 2) with a steel stamp of approximately 1/8 inch (3 mm) character
size.

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 Table 3
Conversion of Regulator and Safety Outlet Part Numbers
Old Revised
Affected Regulator Regulator Old Safety New Safety
CRA P/N P/N P/N Outlet P/N Outlet P/N
801293-00 801292-00 801292-05 800659-05 800659-06
801293-04 801292-01 801292-06 800659-05 800659-06
801365-10 801366-11 801366-15 800659-03 800659-01
801365-11 801366-10 801366-14 800659-03 800659-01

3. ACCOMPLISHMENT INSTRUCTIONS

WARNING: FAILURE TO FOLLOW THE PROCEDURES IN THIS SERVICE INFORMATION LETTER,

INCLUDING BUT NOT LIMITED TO FAILURE TO READ AND HEED THE WARNINGS IN
THIS SERVICE INFORMATION LETTER, OR ATTEMPTING TO PERFORM ANY OF THE
PROCEDURES IN THIS SERVICE INFORMATION LETTER UNLESS TRAINED IN THE
PROPER USE AND MAINTENANCE OF AVIATION OXYGEN EQUIPMENT, MAY
RESULT IN AN EXPLOSION, ILLNESS, SERIOUS PERSONAL INJURY, OR DEATH.

A. Read and understand all the information in this Service Information Letter before performing any
procedures on the CRA. Perform all procedures in the sequence of operations given. Do not attempt
to perform any of the procedures in this Service Information Letter unless you are trained and
qualified in the proper use and maintenance of aviation oxygen equipment. Maintenance personnel
must know how to avoid the hazards of maintaining aviation oxygen equipment and must comply with
all applicable government regulations.

WARNING: FAILURE TO CONTROL HIGH PRESSURE GASEOUS OXYGEN MAY RESULT IN

SERIOUS PERSONAL INJURY OR DEATH.

B. High pressure oxygen is a hazardous material. When pressurized oxygen is discharged intentionally
or due to equipment failure, the released energy can be highly destructive if not properly controlled.
Do not perform any procedure on an unsecured, charged, cylinder assembly. Also, while oxygen is
not a flammable material, it will accelerate combustion and must be considered a fire hazard. Refer to
paragraph 3.C. below.

WARNING: CONTAMINATION OF OXYGEN EQUIPMENT BY FAILING TO HANDLE OXYGEN

EQUIPMENT IN AN AREA CLEAN OF OIL, GREASE, FLAMMABLE SOLVENTS, OR
OTHER COMBUSTIBLE MATERIALS INCLUDING DUST, LINT, AND FINE METAL
PARTICLES; CONTAMINATION FROM FAILING TO USE CLEAN HANDS, GLOVES,
TOOLS; OR CONTAMINATION BY ANY OTHER MEANS, WHEN HANDLING OXYGEN
EQUIPMENT, MAY RESULT IN FIRE OR EXPLOSION THAT MAY CAUSE SERIOUS
PERSONAL INJURY OR DEATH.
C. If oxygen equipment becomes contaminated with oil, grease, flammable solvents, or other
combustible materials, fire and explosion may occur. Also, many substances and materials that do
not normally burn in air, including dust, lint, and fine metal particles can ignite in the presence of
oxygen. Handle oxygen equipment only in a clean area and with clean hands, gloves, and tools.

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 WARNING: FAILURE TO USE ONLY OXYGEN COMPATIBLE PRODUCTS, EQUIPMENT, AND
MATERIALS WHEN CARRYING OUT THE PROCEDURES IN THIS SIL, CAN BRING
ABOUT A VIOLENT REACTION RESULTING IN FIRE OR EXPLOSION THAT MAY
CAUSE SERIOUS PERSONAL INJURY OR DEATH.

D. Many commonly used materials may react violently in the presence of high pressure oxygen. Only
equipment and materials known to be compatible with oxygen should be used. Do not substitute
other equipment or materials such as elastomeric o-rings, gaskets, seals, and metal components,
even if they look the same.

WARNING: FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING SERVICE OR

OVERHAUL PROCEDURES DESCRIBED IN THIS MANUAL MAY CAUSE INJURY TO
THE EYES.
E. Use eye protection at all times during all service or overhaul procedures.

WARNING: FAILURE TO FULLY DISCHARGE THE OXYGEN FROM THE CRA, COMPONENT
PARTS, OR TEST SETUP PRIOR TO DISASSEMBLY OF ANY PART MAY CAUSE
SERIOUS PERSONAL INJURY OR DEATH.
F. High pressure oxygen is a hazardous material. When pressurized oxygen is discharged intentionally
or due to equipment failure, the released energy can be highly destructive if not properly controlled.
Fully discharge the oxygen from the CRA, component parts, and test setup prior to disassembly of
any part.

NOTE: This SIL is to be accomplished off-wing. Do not use the Overhaul Manual H-173 to
accomplish this SIL. Follow the steps below which apply during a hydrostatic test, an
overhaul, a repair or strictly for the replacement of the safety outlet.
G. In a clean, grease-free area, bleed the oxygen from the cylinder.
H. Remove the regulator from the cylinder.
I. Remove and discard the safety outlet assembly (P/Ns 800659-03 or 800659-05) from the regulator.
J. Apply a light film of oxygen compatible lubricant to the exposed surface of the gasket in the safety
adapter (P/N 10001420) of the new safety outlet assembly (P/Ns 800659-01 or 800659-06). Refer to
Figure 1.

K. Thread the safety adapter (P/N 10001420) into the regulator outlet and torque to 325 inylbs
(36.7 Nym). Refer to Figure 1.
L. Hold the safety adapter with a wrench and torque the safety outlet nut (P/Ns 10723-00 or 22605-03)
to 300 inylbs (33.9 Nym) into the safety adapter (P/N 10001420).

M. Re-identify the regulator.

(1) Stamp the S/N from the current identification label onto the replacement identification label P/N
2824-00 (see Figure 2).
(2) Stamp the revised P/N from Table 3 onto the replacement identification label P/N 2824-00 (see
Figure 2).
(3) Remove the current identification label from the regulator.
(4) Attach the replacement identification label P/N 2824-00 to the regulator in place of the label that
was removed.

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 N. Use the appropriate technical documents to complete the hydrostatic test, overhaul, or repair if
required or do a leak test.
O. After the service has been completed, attach the P/N 10014464 Label (Figure 3) to the cylinder in the
location shown in Figure 4.
NOTE: On smaller cylinders the label can be placed in a location just below the identification label.
NOTE: Locate the label P/N 10014464 so that it will not be covered by the mounting band that will
hold the cylinder after installation.
P. Affected units listed in Table 1 can be shipped in an empty condition to an authorized repair facility
listed in paragraph 4. Appendix to have the SIL accomplished.

Safety Outlet Installation

Figure 1

Replacement Identification Label P/N 2824-00

Figure 2

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 US DOT Compliance Label P/N 10014464
Figure 3

Location of the Compliance Label on the Cylinder

Figure 4

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4. APPENDIX
Contact Information:
AVOX Services Inc. IN-Services Europe
225 Erie Street 7, Avenue du Parana
Lancaster, NY 14086-9502 USA B.P. 303
91958 Courtaboeuf Cedex
Tel: 716-683-5100
France
Fax: 716-686-1751
Customer Services
Celine Robitaille
IN-Services Asia
Phone: 33 1 64 86 69 19
80 Chun Choi Street
Email: crobitaille@intertechnique.zodiac.com
Tseung Kwan O Industrial Estate
New Territories
Hong Kong, China IN-Services (Middle East)
Abu Dhabi International Airport
General Manager
P.O. Box 106675
Sebastien WEBER
Cargo Village Area
Email: weber.inasia@haeco.com
Abu Dhabi, U.A.E.
Customer Support Administration-
Shirley Huen GM and Sales Manager
Email: huen.inasia@haeco.com Boulouafi Bouach
Phone: (852) 2260 4050 Phone: (971) 2 672 5257
Fax: (852) 2260 4052 Email: bbouach@inservices-alrumaithy.com

AVOX-EROS Services
6734 Valjean Ave
Van Nuys, CA 91406
Phone: 818-787-3852
Fax: 818-435-0992
Jean-Marc LeMaitre
Director of Marketing & Customer
Relations
Email: ptaylor@avox-eros.zodiac.com
818-435-0911

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